Family of cutting inserts, milling cutting tool, and cutting insert

ABSTRACT

A family of cutting inserts includes a plurality of different inserts, each having a different geometry. Each insert of the plurality of different inserts is adapted to be mounted in a common insert-receiving pocket on a toolholder of a milling cutting tool so that an outer diameter generated by the milling cutting tool is the same, regardless which insert of the plurality of inserts is mounted in the pocket.

BACKGROUND AND SUMMARY

The present invention relates generally to cutting inserts and, moreparticularly, to families of cutting inserts usable in the sametoolholders.

In milling cutting operations, use of an insert of circular shapepermits providing a depth of cut equal to one half of insert diameter,or generating a radius at the bottom of a workpiece. The leading angleof a milling cutting tool with a circular insert depends on depth ofcut. The higher the depth of cut is, the higher the leading angle is. Toreach the maximum material removal rate using circular inserts, theconventional strategy is to machine with high depth and avoid reaching ahigh feed per tooth. This strategy tends to create high radial cuttingforces which are acceptable when the tool overhang is short but whichcreate chatter effects when total tool length becomes large.

With a high feed insert, such as an insert having four cutting edges,the maximum depth of cut is reduced due to the insert shape and,consequently, the leading angle is reduced. To reach the maximummaterial removal rate using a high feed insert, the strategy differsfrom that used with circular inserts. Because the leading angle anddepth of cut is typically reduced in a multi-edge insert relative to acircular insert, the feed per tooth can be increased. This strategytends to reduce radial cutting forces (at least relative to high depthof cut and/or high leading angle operations), which can be a benefitwhen long overhang is necessary.

When using a finishing insert, the depth of cut and the leading angleare generally reduced further, and feed rate can be increased further.

When switching from use of one type of insert to another, it isordinarily necessary to adjust various settings on the CNC machine toaccount for different lengths and diameters of the cutting tool. It isdesirable to provide a milling toolholder on which several differentkinds of inserts could be mounted for operations such as copy milling,face milling, plunging, helical interpolation, and the like. It is alsodesirable to provide inserts that can be mounted on the same toolholderso that, regardless which insert is mounted on the toolholder, the toolwill generate the same diameter and have the same length.

According to an aspect of the present invention, a family of cuttinginserts comprises a plurality of different inserts, each having adifferent geometry, wherein each insert of the plurality of differentinserts is adapted to be mounted in a common insert-receiving pocket ona toolholder of a milling cutting tool so that an outer diametergenerated by the milling cutting tool is the same, regardless whichinsert of the plurality of inserts is mounted in the pocket.

According to another aspect of the present invention, a family ofcutting inserts is provided. Each cutting insert in the family has abottom supporting surface and an axis of rotation and, arranged aroundthe axis of rotation, a plurality of side insert supporting surfaces anda plurality of cutting edge portions corresponding to each of theplurality of side insert supporting surfaces. The cutting edge portionsfor each insert being generally convex and the cutting edge portions forat least some different inserts in the family having differentcurvatures. For each cutting edge, a first plane parallel to the axis ofrotation and tangent to the cutting edge at a face contact point on thecutting edge is disposed at a predetermined distance from a parallelsecond plane extending through the axis of rotation and rotated at apredetermined angle relative to a third plane intersecting acorresponding side insert supporting surface along a line substantiallyperpendicular to the axis of rotation.

According to another aspect of the present invention, a milling cuttingtool arrangement is provided and comprises a toolholder comprising abody and at least one insert-receiving pocket in the body, the at leastone insert-receiving pocket being adapted to receive any one of a familyof cutting inserts.

According to another aspect of the present invention, a cutting insertcomprises a plurality of cutting edges and a plurality of cornersbetween the cutting edges, each cutting edge lying along an arc of arespective circle, a first line extending through a centerpoint of arespective one of the cutting edges and a radial center of therespective circle of the respective one of the cutting edges forming anon-zero angle with a second line extending through the centerpoint ofthe respective one of the cutting edges and a center of rotation of theinsert.

BRIEF DESCRIPTION OF THE DRAWINGS

The features and advantages of the present invention are well understoodby reading the following detailed description in conjunction with thedrawings in which like numerals indicate similar elements and in which:

FIGS. 1A, 1B, and 1C are perspective views of inserts according toaspects of the present invention;

FIG. 2 is a perspective view of a toolholder according to an aspect ofthe present invention;

FIGS. 3A, 3B, and 3C are perspective views of milling cutting toolsaccording to aspects of the present invention;

FIGS. 4A, 4B, and 4C are bottom plan views of inserts according toaspects of the present invention;

FIGS. 5A, 5B, and 5C are perspective views of pockets in toolholdersaccording to aspects of the present invention;

FIGS. 6A, 6B, and 6C are side views of inserts according to aspects ofthe present invention;

FIGS. 7A, 7B, and 7C are bottom plan views of inserts according toaspects of the present invention;

FIG. 8 is a schematic view of parts of a milling cutting tool accordingto an aspect of the present invention illustrating a ramping angle ofthe milling cutting tool;

FIGS. 9A and 9B are bottom plan views of inserts according to aspects ofthe present invention; and

FIG. 10 is a bottom plan view of an insert according to an aspect of thepresent invention.

DETAILED DESCRIPTION

Different inserts 21, 121, 221 of a family of cutting inserts are shownin FIGS. 1A-1C. Each insert 21, 121, 221 has a different geometry, suchas, but not necessarily, having cutting edges that are of differentshapes when viewed in plan. For illustrative purposes, the insert 21 hasa circular shape when viewed in plan, the insert 121 has a four-sidedshape when viewed in plan with cutting edges having radii equal to adiameter of a circle inscribed in the corresponding circular insert 21and with radiused corners between the cutting edges, and the insert 221has a four-sided shape when viewed in plan with cutting edges havingradii greater than the diameter of a circle inscribed in the insert andwith a plurality of (three) chamfers between the cutting edges. Thedifferences in geometry can involve other features of the insert,instead of or in addition to the cutting edges, such as the presence orabsence of chipbreakers, flat or curved wiper surfaces, etc.

Each insert 21, 121, 221 of the plurality of different inserts isadapted to be mounted in a common insert-receiving pocket 23 on atoolholder 25 as seen in FIG. 2, thereby forming a milling cutting tool27 as seen in FIGS. 3A-3C. At least one and, ordinarily, a plurality ofcommon pockets 23 are provided on the toolholder 25 for receiving acorresponding plurality of inserts. Ordinarily, as seen in FIGS. 3A-3C,at any given time, only one type of insert of the family of inserts ismounted on the toolholder, i.e., a plurality of inserts 21, a pluralityof inserts 121, or a plurality of inserts 221, however, it is alsopossible to mount different types of the inserts of the family ofinserts on a single toolholder, e.g., an insert 21 with an insert 121and/or 221.

According to an aspect of the invention, the pockets 23 and the inserts21, 121, 221 are configured such that an outer diameter D generated by amilling cutting tool 27 formed when inserts are mounted in thetoolholder can be the same, regardless which of the inserts 21, 121, or221 in the pocket are provided in the pockets. An axial length L of themilling cutting tool 27 measured from a forwardmost cutting edge 29,129, 229 on each insert of the plurality of inserts 21, 121, 221, whenmounted in the pocket 23, to a rearwardmost point 31 on the toolholdercan be the same regardless which insert of the plurality of inserts ismounted in the pocket.

According to an aspect of the invention, to provide a milling cuttingtool 27 that generates the same diameter D regardless which of theinserts 21, 121, or 221 is mounted in the pockets of the toolholder 25,as seen for example in FIGS. 4A-4C, each insert of the plurality ofdifferent inserts has at least one insert supporting surface 33, 133,233 having a plane P, and a cutting edge 35, 135, 235 associated withand on a substantially opposite side of the insert from the at least oneinsert supporting surface. The inserts 21, 121, 221 have a central axisA extending between a top 37, 137, 237 (FIGS. 1A-1C) of the insert and abottom 39, 139, 239 of the insert. Ordinarily, the insert is indexableto a plurality of different positions about the central axis A to permitusing different cutting edges on the insert.

As seen in FIGS. 4A-4C, for a family of cutting inserts 21, 121, 221,each cutting insert has a bottom supporting surface 39, 139, 239 and anaxis of rotation A. A plurality of side insert supporting surfaces 33,45, 133, 145, 233, 245 and a plurality of cutting edge portions 35, 29,135, 129, 235, 229 corresponding to each of the plurality of side insertsupporting surfaces are arranged around the axis of rotation A. Thecutting edge portions for each insert 21, 121, 221 are generally convexand the cutting edge portions for different inserts having differentcurvatures. For each cutting edge portion, a first plane P1 parallel tothe axis of rotation A and tangent to the cutting edge at a face contactpoint Y (or some other, arbitrary or non-arbitrary point) on the cuttingedge is disposed at a predetermined distance X from a parallel secondplane P2 extending through the axis of rotation and rotated at apredetermined angle α relative to a third plane P3 intersecting acorresponding side insert supporting surface along a line 41, 141, 241(FIGS. 4A-4C and 10) substantially perpendicular to the axis of rotationA. The line 41, 141, 241 may be, but need not be, a line defining a baseof the side insert supporting surface. FIGS. 4A-4C show the angle αmeasured relative to a plane P3′ parallel to plane P3 but offsetrelative to the plane P3 to extend through the axis of rotation like theplane P2.

In the family of inserts shown in FIGS. 4A-4C, one cutting insert 21 ofthe family of cutting inserts is substantially circular when viewedalong the axis of rotation A. The predetermined distance X for all ofthe inserts is therefore equal to the radius of the cutting insert 21.If a circular insert is not a member of the family of inserts, thedistance X can be substantially any desired value.

The predetermined angle α can be determined for a single insert of thefamily of inserts and applied to the rest of the members of the family.FIG. 10 shows how the angle α is determined for the insert 121 of thefamily of inserts 21, 121, 221. The angle α is substantially equal to adifference between an offset angle θ of the cutting insert 121 and anangle of rotation M of the third plane P3 relative to a fourth plane P4parallel to the axis of rotation and intersecting opposite end points161 of the cutting edge (edge 129 shown for purposes of illustration)corresponding to the side insert supporting surface (surface 145 shownfor purposes of illustration) intersected by the third plane, the anglesbeing considered when the insert is viewed in “plan” along the axis ofrotation A of the insert. The offset angle θ is measured between thefirst plane P1 and a fourth plane P4′ parallel to the axis of rotation Aand extending between end points 161 of the cutting edge 129 (parallelto plane P4). In other words, the angle α is measured between the planeP1 (parallel to P2) and the plane P3. The angle α is described as being“substantially” equal to the difference between the offset angle θ andthe angle of rotation M because it may be desirable to further adjustthe angle for purposes of fine tuning, such as if the insert is orientedat a non-zero axial angle, i.e., a plane of the bottom surface 49 of thepocket 23 is not parallel to the axis of rotation LA of the toolholder25. For example, depending upon the axial angle of the insert in thetoolholder 25, it may be desirable to further adjust the angle α, e.g.,±about 1°.

In an embodiment according to an aspect of the invention, a secondcutting insert 21 of the family of cutting inserts is substantiallycircular when viewed along the axis of rotation, and the predetermineddistance X is equal to the radius R21 of the cutting insert. Theplurality of cutting edges 29, 35 of the first cutting insert 121 have aradius R121 substantially equal to a diameter of the second cuttinginsert, i.e., 2 times R21. The cutting edges of non-circular inserts donot, however, have to be arcs of circles, i.e., they need not have aparticular radius.

The predetermined angle α will ordinarily be between 15° and −15° and,preferably, greater than 0°. The side insert supporting surfaces may bebut need not be substantially planar. Where the side insert supportingsurfaces are described as having a plane, it will be understood thatthis can refer to a reference plane associated with the surface and thatthe surface is not necessarily planar.

To provide a milling cutting tool 27 as shown in FIGS. 3A-3C that hasthe same axial length L measured from a forwardmost cutting edge 29,129, 229 on each insert of the plurality of inserts 21, 121, 221, whenmounted in the pocket 23, to a rearwardmost point 31 on the toolholder25, the relationship between the cutting edge 29, 129, 229 and theinsert supporting surface 45, 145, 245 on the opposite side of theinsert is the same as the relationship between the cutting edge 35, 135,235 and the insert supporting surface 33, 133, 233 on the opposite sideof the insert. The relationship can and ordinarily does apply to anyinsert supporting surface and the associated cutting edge on theopposite side of the insert from the insert supporting surface so that,regardless how any insert is indexed about the axis A, the millingcutting tool 27 will generate the same diameter D and have the sameaxial length L.

The inserts 21, 121, 221 as shown in, for example, FIGS. 1A-1C are shownhaving integrated anvils 47, 147, 247 such as are disclosed in EP 0 458003 B1, which is incorporated by reference. The height of the integratedanvil 47, 147, 247 is ordinarily about 15% of the total insert 21, 121,221 thickness. Regardless whether an anvil is provided, each of theinserts 21, 121, 221 can be configured so that a circle inscribed in theinserts and tangent to the lowest point on each insert supportingsurface has the same diameter for each insert. This structure canfacilitate fitting the different insert shapes into toolholder pocketsof the same size.

As seen in FIG. 5A-5C, the pocket 23 ordinarily includes a flat bottomsurface 49, and flat, generally axially extending and flat, generallyradially extending side abutment surfaces 51 and 53. The bottom surface39, 139, 239 of the insert, and the insert supporting surfaces 33, 133,233 and 45, 145, 245 are ordinarily, but not necessarily, substantiallyflat and planar, at least at points where they are intended to abutcorresponding abutment surfaces 49, 51, 53 in the pocket 23. When aninsert 21, 121, 221 is mounted in a pocket 23 having two abutmentsurfaces 51 and 53, two successive insert supporting surfaces 33, 133,233 and 45, 145, 245 will contact the abutment surfaces. The insertsillustrated in the present application are indexable to four differentpositions to utilize four different cutting edges provided on the insertand it will be appreciated that the identification of the insertsupporting surfaces by particular reference numerals is for purposes ofdiscussion only, and that the insert is typically rotationallysymmetrical about the central axis A in four different positionsoriented at 90° to each other. In other embodiments, the insert can beindexable to some number of different positions other than four, such astwo or eight different positions.

In other embodiments (not shown), the bottom surfaces of the insert andthe pocket may be provided with structures such as mating groovedsurfaces to facilitate, among other things, seating of the insert withreduced possibility of rotation. In other embodiments, the bottom andinsert supporting surfaces of the insert and/or the bottom and abutmentsurfaces of the pocket may be provided with structures such as recessesto facilitate, among other things, ensuring multi-point contact betweenthe insert surfaces and the corresponding pocket surfaces. The radialand axial abutment surfaces in the pocket need not and ordinarily do notextend only in the radial and axial directions relative to thetoolholder. As seen in FIG. 8, for example, the radial abutment surface51 (shown in phantom) extends at an angle AR to the axis LA of thetoolholder 25, the axial abutment surface 53 (shown in phantom) extendsat an angle AA to the axis of the toolholder, and the bottom abutmentsurface 49 (shown in phantom) extends at the angle K (FIG. 2) to theaxis of the toolholder.

For purposes of discussion, it will be understood that the radial andaxial abutment surfaces 51 and 53 are substantially flat and planar, atleast where they abut the insert supporting surfaces, and that theradial and axial abutment surfaces extend only radially and axiallyrelative to the toolholder 25. Likewise, merely for purposes ofdiscussion, it will further be understood that the insert supportingsurfaces 33, 133, 233 and 45, 145, and 245 are substantially flat andplanar, at least where they abut the insert supporting surfaces, andthat they are substantially perpendicular to each other.

The flat surfaces of the abutment surfaces and the insert supportingsurfaces act as seating faces and secure the insert against rotationrelative to the toolholder during machining operations. The pocket 23shown in FIG. 5A shows the general area of contact C′ on the radial andaxial abutment surfaces 51 and 53 of the insert-supporting surfaceportions 33 and 45 (not shown in FIG. 5A) of the insert 21, the pocket23 shown in FIG. 5B shows the general area of contact C″ on the radialand axial abutment surfaces 51 and 53 of the insert supporting surfaceportions 133 and 145 (not shown in FIG. 5B) of the insert 121, and thepocket 23 shown in FIG. 5C shows the general area of contact C′″ on theradial and axial abutment surfaces 51 and 53 of the insert supportingsurfaces portions 233 and 245 (not shown in FIG. 5C). The area ofcontact is not necessarily the same for each insert in the family ofinserts. The area of contact is also not necessarily the same for theabutment of any particular pair of insert supporting surfaces and theirassociated abutment surfaces, even though FIG. 5A shows each of theareas of contact C′ being substantially the same, FIG. 5B shows each ofthe areas of contact C″ being substantially the same, and FIG. 5C showseach of the areas of contact C′″ being substantially the same.Ordinarily, as seen in FIGS. 4A-4C and 6A-6C, the insert supportingsurfaces 33, 133, 233 and 45, 145, 245 of an insert 21, 121, 221 in thefamily of inserts will begin at the top of the integrated anvil 47, 147,247 and finish at some point in the flank face 55, 155, 255 and 57, 157,257 of the insert, ordinarily below the cutting edge 29, 129, 229 and35, 135, 235.

As seen in FIGS. 6A, 6B, and 6C, the flat insert supporting surfaces 33,133, 233 and 45, 145, 245 will ordinarily define a larger angle with aline parallel to the central axis A than the flank face 55, 155, 255 and57, 157, 257. In an embodiment, the insert supporting surfaces 33, 133,233 and 45, 145, 245 define an angle I of 22° with the line parallel tothe central axis A and the flank faces 55, 155, 255 and 57, 157, 257define an angle J of 15° with the line parallel to the central axis A.

In the embodiments of the inserts 21, 121, 221 shown in FIGS. 1A-1C,3A-3C, and 4A-4C, the inserts have four insert supporting surfaces andfour associated cutting edges on opposite sides of the insert from theinsert supporting surfaces. Adjacent insert supporting surfaces can beoriented at angles of 90° around the axis of rotation A of the insert.Other embodiments may, of course, have more or fewer insert supportingsurfaces and cutting edges.

The height of the insert supporting surfaces 33 and 45 of the insert 21is about 75% of the total height of the insert. An insert such as theinsert 21 is particularly useful in providing a high maximum depth ofcut ap, usually with ap=Insert Diameter/2=R21 as seen in FIG. 7A, and ittypically has a relatively large setting or leading angle Kr. When theinsert 21 is used in an application where it provides a high depth ofcut ap, it is typically not used to provide a high feed rate. Using amilling tool 27 provided with circular inserts 21 in a manner to reachmaximum material removal rate ordinarily involves a high depth of cutap, without a high feed rate, and high radial cutting forces. Short tooloverhang is preferred in such operations to avoid chatter.

In the embodiment of the high feed insert 121 shown in FIGS. 1B, 3B, and4B, the insert is four-sided and has insert supporting surfaces 145 and133 disposed on opposite sides of the insert from cutting edges 129 and135, respectively. The cutting edges 129 and 135 are arcs of a circlehaving a radius R121 (FIG. 7B) equal to a diameter of a circle inscribedin the insert 21. The diameter of a circle inscribed in the insert 121may be smaller than the diameter of the circle inscribed in the insert21 to facilitate providing inserts that, when mounted on the sametoolholder, will generate the same diameters and lengths. There are fourinsert supporting surfaces and adjacent insert supporting surfaces canform angles of 90°. As seen in FIG. 4B, the insert supporting surfaces145 and 133 can be “rotated” or “offset” so that the line 141 defines anangle M with a line 159 extending through end points of the cuttingedges 129 and 135 at corners 161 of the insert 121.

In an embodiment of the high feed insert 121, the angle M is preferably9° and could be between 7° and 9° (or some other range, depending uponthe configuration of the insert and the toolholder). As seen in FIG. 8,offsetting the insert supporting surfaces facilitates increasing aramping angle compared to a “centered” insert supporting surface, i.e.,one where the angle M is 0°. In particular, the rotation or offset ofthe insert supporting surfaces 133 and 145 (shown in phantom) can exposemore of a ramping cutting edge 171 (shown circled in FIG. 8), therebyfacilitating entry into a workpiece with a milling cutting tool (notshown in FIG. 8) that does not have cutting inserts in a center of thetool by means of a larger ramping angle RA between the end of theramping cutting edge and the tip of the cutting edge of the insert(shown in phantom) when rotated 180° about the longitudinal axis LA ofthe cutting tool.

The maximum depth of cut ap (FIGS. 7B and 8) of the high feed insert 121is lower than with the circular insert 21, but the feed per tooth can beincreased. By offsetting the insert supporting surfaces 133 and 145, itis possible to increase the maximum depth of cut ap relative to aninsert with the insert supporting surfaces centered opposite the cuttingedges. The leading angle Kr is decreased compared to an equivalent roundshape insert. A milling tool 27 provided with high feed inserts 121tends to reduce radial cutting forces, which can be a benefit when tooloverhang is long.

In the embodiment of the high feed finishing insert 221 shown in FIGS.1C, 3C, and 4C the insert is four-sided and has insert supportingsurfaces 245 and 233 disposed on opposite sides of the insert fromcutting edges 229 and 235, respectively. The cutting edges 229 and 235are arcs of a circle having a radius R221 (FIG. 7C) greater than adiameter of a circle inscribed in the insert 221, e.g., radius=50 mm, ormore, e.g., 100 mm, 200 mm, etc.

The radius R221 can be “offset” as seen in FIG. 7C in the sense thateach cutting edge can be considered to lie along an arc of a respectivecircle, and a first line 1L (coinciding with radius R) extending througha centerpoint CP of each cutting edge 229, 235 and a radial center RC ofits respective circle forms a non-zero angle G with a second line 2Lextending through the centerpoint of each cutting edge and an axialcenter (of rotation) A of the insert. By way of contrast, the line 1Lcoincident with the radii R21 and R121 of and extending through thecenterpoint CP of the cutting edges in the inserts 21 and 121 shown inFIGS. 7A and 7B forms a 0° angle with the line 2L extending through thecenterpoint of the cutting edges and the central axis A of the inserts.

There are four insert supporting surfaces and adjacent insert supportingsurfaces can form angles of 90°. As seen in FIG. 4C, the insertsupporting surfaces 245 and 233 can be “rotated” or “offset” so that theline 241 defines an angle N with a line 259 extending through end pointsof the cutting edges 229 and 235 at corners 261 of the insert 221. Asdescribed differently with reference to FIG. 7C, the insert supportingsurfaces can be considered to be “rotated” or “offset” in the sense thateach insert supporting surface forms a non-zero angle N with a thirdline 3L perpendicular to the second line 2L. In an embodiment, the angleN is preferably 3.5° and may be between 0.5° and 5° (or some otherrange, depending upon insert and toolholder configuration), whichfacilitates decreasing the leading angle for small depth of cut with alarge radius cutting edge which tends to be more useful in a finishingoperation. The “rotation” of the angle N in the insert 221 and the angleM in the insert 121 can be in the opposite direction relative to thelines 259 and 159, respectively, to achieve desired results,particularly where the radial and axial abutment surfaces 51 and 53 inthe pocket 23 form an angle with the axis LA of the toolholder 25 andwith a perpendicular to the axis of the toolholder.

Regardless how many cutting edges are provided on an insert, in at leastsome inserts according to embodiment of the present invention, eachcutting edge defines an arc of circle and each insert supporting surfaceof the second one of the plurality of inserts has a plane P. A radialline 2L bisecting an arc of a circle of the cutting edge can beperpendicular to an insert supporting surface on the same side of theinsert, as is the case with the insert 21 shown in FIG. 4A, ornon-perpendicular to an insert supporting surface on a same side of theinsert, as is the case with the inserts 121 and 221 shown in FIGS. 4Band 4C.

The pocket 23, in addition to having a bottom surface 49, and radial andaxial abutment surfaces 51 and 53, will ordinarily have a recess 63 atthe intersection of the radial surface and the bottom surface, a recess65 at the intersection of the axial abutment surface and the bottomsurface, and a recess 67 at the intersection of the axial abutmentsurface and the radial abutment surface. A further recess 69 can beprovided behind the radial abutment surface 51. The recesses 63, 65, 67,and 69 can facilitate seating of the inserts in the pocket 23 withoutinterference between corners of the inserts and corners of the pocket.

As seen in FIG. 2, the axial angle K of the insert pocket 23—the anglethat the bottom surface 49 of the pocket forms with the longitudinalaxis LA of the toolholder 25—can be set at an angle. The angle K willordinarily be selected depending upon the angle of the insert flankfaces 55, 155, 255 and 57, 157, 257. Where the insert flank faces 55,155, 255 and 57, 157, 257 form an angle J of 15°, for example, the axialangle K of the insert pocket may be set at, for example, 9°, which canfacilitate machining of various materials, particularly “sticky”materials such as titanium, stainless steel, and high temperaturealloys.

In the circular insert 21, the “corners” 61 between adjacent cuttingedges are ordinarily continuations of the circular edge surface. In thehigh feed insert 121, the corners 161 between curved cutting edges aretypically radiused.

In an embodiment of the finishing insert 221, the corners 261 betweencurved cutting edges are typically chamfered to form three generallyflat chamfer surfaces 273 a, 273 b, 273 c (FIG. 7C) that form differentangles with the line 259 through ends of the cutting edges. In anembodiment the surface 273 a forms a 30° angle, the surface 273 b formsa 45° angle, and the surface 273 c forms a 60° angle. These chamferssurfaces 273 a, 273 b, 273 c, coupled with offset insert supportingsurfaces and an offset circular arc of the cutting edge, help toincrease depth of cut with a low setting angle. For example, if thedepth of cut is relatively small, the setting angle may be 30° insteadof immediately transitioning to, say, a 45° setting angle.

In embodiments of the insert 21, the flank surfaces 55 and 57 betweenthe cutting edges 29 and 35 are portions of a truncated cone. However,as seen in the embodiment 21′ shown in FIG. 9A, flat wiper surfaces 75′can be provided beneath straight wiper edges 77′ along an otherwisecircular cutting edge 29′ having radius R or, as seen with respect tothe embodiment 21″ shown in FIG. 9B, curved wiper surfaces 75″ can beprovided beneath curved wiper edges 77″, the wiper edges RWE having aradius different (generally larger) than the radius R of the rest of thecutting edge 29″ and having a radius different from a radius of theflank 55″ at the same height along the axis A of the insert. The flanksbeneath the cutting edges of the inserts 121 and 221 are ordinarilycurved portions of truncated cones but, if desired, may have wipersurfaces that are flat or that have radii different from the radii ofthe flanks. Using inserts with wiper surfaces can produce high qualitysurface finishes.

The inserts 21′ and 21″ have one or more insert supporting surfaces 33′and 33″ corresponding to a respective wiper surface 75′ and 75″ and arespective wiper edge 77′ and 77″. Each insert supporting surface 33′and 33″ extends through a first angle 31 (not necessarily the same foreach insert) measured through the axis of rotation A of the insert, andthe respective wiper edge 77′ and 77″ and respective wiper surface 75′and 75″ extends through a second, angle β2 measured through the axis ofrotation A of the insert. A centerline γ1 bisecting the first angle β1forms a non-zero angle δ (not necessarily the same for each insert) witha centerline γ2 bisecting the second angle β2.

In the present application, the use of terms such as “including” isopen-ended and is intended to have the same meaning as terms such as“comprising” and not preclude the presence of other structure, material,or acts. Similarly, though the use of terms such as “can” or “may” isintended to be open-ended and to reflect that structure, material, oracts are not necessary, the failure to use such terms is not intended toreflect that structure, material, or acts are essential. To the extentthat structure, material, or acts are presently considered to beessential, they are identified as such.

While this invention has been illustrated and described in accordancewith a preferred embodiment, it is recognized that variations andchanges may be made therein without departing from the invention as setforth in the claims.

The disclosures in Swedish patent application Nos. 0801512-5 and0801513-3, from which this application claim priorities, areincorporated herein by reference.

1. A family of cutting inserts, comprising a plurality of differentinserts, each having a different geometry, wherein distances betweencutting edges and corresponding insert supporting surfaces are selectedfor each insert of the plurality of different inserts so that eachinsert is adapted to be mounted in a common insert-receiving pocket on atoolholder of a milling cutting tool so that an outer diameter generatedby the milling cutting tool is the same, regardless which insert of theplurality of inserts is mounted in the pocket.
 2. The family of cuttinginserts as set forth in claim 1, wherein an axial length of the millingcutting tool measured from a forwardmost cutting edge on each insert ofthe plurality of inserts, when mounted in the pocket, to a rearwardmostpoint on the toolholder is the same regardless which insert of theplurality of inserts is mounted in the pocket.
 3. The family of cuttinginserts as set forth in claim 1, wherein at least one of the pluralityof inserts is substantially circular when viewed in plan.
 4. The familyof cutting inserts as set forth in claim 1, wherein at least a first oneof the plurality of inserts has a plurality of sides when viewed inplan.
 5. The family of cutting inserts as set forth in claim 4, whereineach side of the first one of the plurality of inserts comprises acutting edge and an insert supporting surface.
 6. The family of cuttinginserts as set forth in claim 5, wherein each cutting edge of the firstone of the plurality of inserts defines an arc of circle and each insertsupporting surface of the first one of the plurality of inserts has aplane.
 7. The family of cutting inserts as set forth in claim 6, whereina radial line bisecting an arc of a circle of a cutting edge of thefirst one of the plurality of inserts is non-perpendicular to an insertsupporting surface on a same side of the first one of the plurality ofinserts.
 8. A family of cutting inserts, each cutting insert in thefamily of cutting inserts having a bottom supporting surface and an axisof rotation and, arranged around the axis of rotation, a plurality ofside insert supporting surfaces and a plurality of cutting edge portionscorresponding to each of the plurality of side insert supportingsurfaces, the cutting edge portions for each insert being generallyconvex and the cutting edge portions for at least some different insertsin the family having different curvatures, wherein, for each cuttingedge, a first plane parallel to the axis of rotation and tangent to thecutting edge at a face contact point on the cutting edge is disposed ata predetermined distance from a parallel second plane extending throughthe axis of rotation and rotated at a predetermined angle relative to athird plane intersecting a corresponding side insert supporting surfacealong a line substantially perpendicular to the axis of rotation.
 9. Thefamily of cutting inserts as set forth in claim 8, wherein thepredetermined angle is substantially equal to a difference between anoffset angle of a first cutting insert of the family of cutting inserts,the offset angle (θ) being measured between the first plane and a fourthplane parallel to the axis of rotation and extending between oppositeend points of the cutting edge, and an angle of rotation of the thirdplane relative to the fourth plane.
 10. The family of cutting inserts asset forth in claim 8, wherein a second cutting insert of the family ofcutting inserts is substantially circular when viewed along the axis ofrotation, and in that the predetermined distance is equal to the radiusof the cutting insert, and wherein the plurality of cutting edges of thefirst cutting insert have a radius substantially equal to a diameter ofthe second cutting insert.
 11. The family of cutting inserts as setforth in claim 8, wherein the predetermined angle is between −15° and15°and, more preferably, between 0° and 15°
 12. The family of cuttinginserts as set forth in claim 8, wherein the side insert supportingsurfaces are substantially planar.
 13. A milling cutting toolarrangement, comprising a toolholder comprising a body and at least oneinsert-receiving pocket in the body, wherein the at least oneinsert-receiving pocket is adapted to receive any one of the family ofcutting inserts in claim
 1. 14. A cutting insert comprising a pluralityof cutting edges and a plurality of corners between the cutting edges,each cutting edge lying along an arc of a respective circle, wherein afirst line extending through a centerpoint of a respective one of thecutting edges and a radial center of the respective circle of therespective one of the cutting edges forms a non-zero angle with a secondline extending through the centerpoint of the respective one of thecutting edges and a center of rotation of the insert.
 15. The cuttinginsert as set forth in claim 14, wherein an insert supporting surfacecorresponding to and on an opposite side of the insert from each cuttingedge, each insert supporting surface forms a non-zero angle with a thirdline perpendicular to the second line.